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Even if you design mechanical components satisfying mechanical strength criteria it may fail due to a phenomenon called
fatigue. Historically many design disasters have happened by neglecting effect of Fatigue.In this video lecture we will
learn how to predict and quantify fatigue effect.
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Fig.1 Two methods to break metal wire, Either bend it upward and downward repetitively or pull it
Your answer is obviously the second option. Because this method requires less effort compared to the first case. This is a
well known example of fatigue failure. So how does material fail due to fatigue? To get answer for this question let us
have a close look at stress variation in wire cross section.
When you bend it downwards bending stress induced is in the wire cross section. There will be tension at top area and
compression at bottom area. When wire is at equilibrium there will not be any stress on wire cross section. When wire is
bending upwards there will be compression at top and tension at bottom.
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Fig.2 Stress variation in wire crosssection, as wire is bent downward and upward
So if you trace stress induced at a point with respect to time it will vary like this. As a fluctuating stress with time.
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Fig.4 Some practical cases which could result in fatigue failure, if not designed properly
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The same phenomenon can happen for axle of this motor where it is undergoing fluctuating stress due to gravity effect of
this mass. A rail wheel when it is in contact with with the track produces a high contact stress, but when the wheel
rotates stress gets relieved. When it comes back to original position again contact stress arises. So this also is a case of
fluctuating stress case. Again will lead to fatigue failure if we do not design it carefully. Same is the case with a gear pair.
Here contact stress arised at contact point fluctuates with time.
Fig.5 Number of cylces for fatigue failure increases with decrease in stress amplitude
So this will follow a trend like this, but not forever. You can see after particular stress amplitude, even with slight
decrease in stress number of cycles required to make it fail increases drastically.
Fig.6 Stress amplitude Vs number of cycles, green region represents safe design area
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Or in short if you have stress amplitude below this limit number of cycles to make to fail jumps ton infinity. Or material
never fails after this limit. the material never fails. This limit is known as endurance limit; below endurance limit it is
safe to operate the material. Engineers always try to design their components by keeping stress amplitude below
endurance limit. You can see that endurance limit is way below ultimate stress value.
Fig.8 Use of Goodman diagram to find safe stress amplitude when stresmm mean value is not zero
Similar analysis can be done considering, safe limit of amplitude zero condition as yield strength of material. This is
known as Soberberg diagram. Generally Goodman analysis is the most preferred one.
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